DIY rack for 100 series

[ElHefe]

There are lots of great rack options out there, but I wanted to start with something simple and expand as needed. All in, I’ll be at ~35% of cost of a fully prefabbed rack with all parts + shipping.

I started by deleting my roof rack and sealed the replacement bolts with silicone. These will need to be removed for the install.

 

[ElHefe]

Next I dreamed for a long time about what would be the best approach for the brackets. It would involve a ton of bending and I was concerned that that would weaken the aluminum stock I was going to use. Then I found out Gamiviti makes universal fit (for LC/LX series) brackets. They are not “cheap” but they are not *cheap*. I ordered four since I’m starting with the original four mounting points for my 2001. They arrived. Absolutely incredible. Worth every penny and more. Loads of adjustability and I will have no doubts about strength. I could shake the entire truck from one mount without any strain.

 

[ElHefe]

Assembled them and went out to the truck. Mounted them up in place to take some final measurements.

Information that might be valuable to others:

End of bracket to end of bracket:

Front = 51 inches
Rear = 48 inches

 

[ElHefe]

I plan on ordering aluminum extrusion (3 inch wide by 1 inch tall) at 52 inches. That’s approximately this wide at the front and rear (with hand)

 

[ElHefe]

Next important measurement is the bracket height from the (top) channel lip. It is approximately 3 inches at front and rear.

 

[ElHefe]

I am going to start with aluminum extrusion cross bars that will be 52 inches wide. Then I will add aluminum bar stock that is 3 inches tall by 84 inches by .25 inches. That will approximately this height.

I will then add one inch by one inch aluminum extrusion cross bars.

 

[NoVaGator]

following....

 

[knewstance]

Also following, interested to see how things turn out for you.

 

[Cola]

@ElHefe What I ended up doing as well. Gamiviti mounts. For the crossbars I just ordered front runner load bars since I wanted the ability to use m8 bolts. For the rest I got extruded aluminum precut from 8020.net. have 2 100 watt solar panels, an awning, and shower tent mounted. Great adjustability and a fraction the cost of a prebuilt rack.

 

[JunkCrzr89]

Similar to what I did @ElHefe. I think all total I’m ~$300 in this homemade rack setup, which included the aluminum, Trail Tailor mounts, and front runner fairing.

 

[ElHefe]

@Cola @JunkCrzr89 great ideas from both of you. I ended up going with tnutz.com and got it longer than I initially planned (easier to cut than to add).

The FrontRunner fairing is $189. Worth it?

 

[Cola]

@Cola @JunkCrzr89 great ideas from both of you. I ended up going with tnutz.com and got it longer than I initially planned (easier to cut than to add).

The FrontRunner fairing is $189. Worth it?

Yes worth it. I have the fairing as well. I think it cleans up the look. And completely eliminated wind noise. @JunkCrzr89 that's impressive, best DYI rack I've seen. Looks like a silver front runner rack

 

[ElHefe]

Which size did you get?

 

[Cola]

Which size did you get?

1345mm/1425mm(W)

mine are basically to the front mounts side to side

 

[JunkCrzr89]

The FrontRunner fairing is $189. Worth it?

I got the fairing *used* from a local Mudder for $80 So yes, def worth it! It’s the 1475mm version, which extends beyond the gutter about 1” on both sides. Will probably cut that off. Otherwise it works great and has a ton of adjustability to help mask any minor measuring/cutting mishaps (you’re probably better with a tape measure!).

@JunkCrzr89 that's impressive, best DYI rack I've seen. Looks like a silver front runner rack

Thanks! It works well enough at what I need it to do, though is a bit heavier than I would’ve liked despite being aluminum. Plus side is that I made it for so little cash relative to racks on the market that I don’t care too much if it gets damaged

 

[heckler]

I got the fairing *used* from a local Mudder for $80 So yes, def worth it! It’s the 1475mm version, which extends beyond the gutter about 1” on both sides. Will probably cut that off. Otherwise it works great and has a ton of adjustability to help mask any minor measuring/cutting mishaps (you’re probably better with a tape measure!).

Thanks! It works well enough at what I need it to do, though is a bit heavier than I would’ve liked despite being aluminum. Plus side is that I made it for so little cash relative to racks on the market that I don’t care too much if it gets damaged

Do you have any more details about the rack you made. Dimensions and where did you get the materials.

 

[JunkCrzr89]

Do you have any more details about the rack you made. Dimensions and where did you get the materials.

I can dig that stuff up for you. I have it all written down somewhere in my home office.

 

[Somebodyelse5]

something like this mebe....

(ignore the slot size on the mounting pads)

 

[JunkCrzr89]

something like this mebe....
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View attachment 2392005

 

[thebeedeegee]

Following, I'm about to order the steel to make my own rack using the Gamiviti mounts as well.